Sakai SW880-1 Operator'S Manual Download Page 5

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MACHINE AND ENGINE IDENTIFICATION NUMBERS

When ordering parts or making inquiries about your machine, the following information is
requested.

(1) Machine model
Indicated on the dashboard in the operator’s station.

(2) Machine serial number

SW880

-1

→

4SW65 –

◯◯◯◯◯

SW990

-1

→

4SW67 –

◯◯◯◯◯

(3) Engine serial number

MACHINE AND ENGINE IDENTIFICATION NUMBERS

– 1 –

Summary of Contents for SW880-1

Page 1: ...whenever you do your work When an instruction manual is lost or is damaged and is not legible replace it immediately The main subjects of this manual are 1 Basic precautions for safety 2 Operation 3 D...

Page 2: ...ps 25 2 1 3 Switches 29 2 1 4 Operating levers pedals 37 2 1 5 Fuse box and Line fuse 39 2 2 Handling and Adjustments 39 2 2 1 Seat adjustment 39 2 2 2 Scraper adjustment and replacement 40 2 2 3 Dise...

Page 3: ...ase 68 2 14 2 Coolant 68 2 14 3 Battery 70 2 15 When the Cold Season is Over 71 2 16 For a Long Storage Period 71 2 17 During the Storage Period 71 2 18 When the Battery has Discharged 72 2 18 1 Conne...

Page 4: ......

Page 5: ...making inquiries about your machine the following information is requested 1 Machine model Indicated on the dashboard in the operator s station 2 Machine serial number SW880 1 4SW65 SW990 1 4SW67 3 E...

Page 6: ...l you must assume responsibility for your own personal safety In this manual and on the machine you will find safety notices Each safety notice starts with a signal word as shown below DANGER Denotes...

Page 7: ...hly Incorrect operation can kill or cause injury It is your responsibility to operate the machine safely Making alterations to the machine Please do not make alterations to the machine without permiss...

Page 8: ...ze yourself with their location and how to operate them Understand the meaning of all the symbols When an instruction manual is lost or is damaged and is not legible replace it immediately Understand...

Page 9: ...of shoulder The operator must make prior checks when moving the machine to a hazardous area under unusual conditions Provide against an accident Decide in advance the means of communication in an emer...

Page 10: ...ll build up If in this state you try to remove the filler caps drain the oil or replace the filters you can get burned Perform this work in accordance with the correct procedures with the machine cool...

Page 11: ...t has been turned off do not touch the muffler exhaust pipe or DPF While the engine is running or immediately after it has been turned off do not touch the muffler exhaust pipe or DPF as they will be...

Page 12: ...ow out Replace them with new ones 1 2 Preparation for Safe Operation Clean the step operator s station and floor board and brake pedal Do not place parts tools or unnecessary articles on the step oper...

Page 13: ...as put it away in the confirmation before it gets on Adjust the operator s seat to your most effective operating position Sit on the operator s seat Adjust the seat so that your back will make contact...

Page 14: ...seat as there is the danger of operational mistakes Pay attention to ventilation Exhaust fumes are dangerous if breathed in When starting the engine in an enclosed area provide good ventilation with...

Page 15: ...Follow all the traffic regulations when driving on a public road Sit in the driver s seat before starting operation Sit in the driver s seat before starting operation Be sure to wear the seat belt whe...

Page 16: ...slope can cause unexpected running down the slope Going down hill at speeds other than low range can cause the machine to run down violently Refrain from inattentive driving Inattentive driving or dr...

Page 17: ...machine after moving it to the nearest safe location Do not operate the machine except from the operator s seat Do not drive in a standing posture Do not throw your legs out or lean forward Be sure t...

Page 18: ...fe loading and unloading If they deflect considerably under load apply wooden blocks to reinforce the ramps To prevent your machine from crosswise slippage keep the ramps free from oil mud debris etc...

Page 19: ...f California to cause cancer and reproductive harm Wash hand after handing Inspect or handle the battery with the engine stopped and the starter switch in the position Keep metallic items such as tool...

Page 20: ...should be as far as possible from the battery 1 9 Towing Towing should only be carried out in emergencies and over short distances A trailer should be used for long distance transport The machine sho...

Page 21: ...t is very dangerous to use damaged or deteriorated tools or to use tools for purposes other than intended Use correct tools for their intended use only Change safety related parts at regular intervals...

Page 22: ...t use fuel for flushing oil Handle fuel and oil in a well ventilated area Check the coolant level in the radiator To check the coolant level stop the engine and allow the engine and radiator to cool d...

Page 23: ...ening them to prevent closing and avoid getting caught in them If there is a need to crawl under the machine after it has been lifted be sure to support it from underneath with a solid prop or block W...

Page 24: ...oolant engine oil and hydraulic fluid will become hot Removing the radiator cap or draining the coolant or oil can burn you Perform this work in accordance with correct procedures after the systems ha...

Page 25: ...otective goggles because of the danger of oil inside or swarfs getting sprayed everywhere by the compressed gas inside Exercise extreme care when replacing and repairing tires Tire installed Disassemb...

Page 26: ...2 1 12 Safety Decals Keep all decals clean If lost replace with new one There are decals other than those shown below Treat them in the same manner as the one shown here WARNING Negligence of these in...

Page 27: ...1 BASIC PRECAUTIONS FOR SAFETY 23 WARNING Negligence of these instructions can lead to accidents SW880 1 SW990 1...

Page 28: ...h Rear spray pump selector switch Spray timer switch 2 OPERATION 2 1 Instruments and Controls 2 1 1 Operator s station Vibration drum selector switch Vibration amplitude selector switch Vibration freq...

Page 29: ...ndation in this manual should be based upon the hour meter readings Temperature gauge Indicates the coolant temperature Zone close to symbol H indicates overheating In case of overheating run the engi...

Page 30: ...ll turn on when the hydraulic oil filter becomes clogged Stop the machine and carry out an inspection Engine oil pressure warning lamp It will flash once when the starter switch is turned to the ON po...

Page 31: ...n any flaw or mist is found on the window contact our branch offices or designated factory Engine check lamp When the start switch is set to the position seld diagnosis of the engine will start When t...

Page 32: ...ambient conditions IMPORTANT For the details of the engine check lamp see the instruction manual of the engine Auto Speed lamp Steady light Goes on when the AUTO SPEED is selected by pressing the AUTO...

Page 33: ...ent the engine has started release the key It will automatically return to the position CAUTION Set the forward reverse F N R lever in the neutral position and press down the parking brake switch befo...

Page 34: ...leased and the indicator lamp goes off WARNING To disengage the brake be sure to press the button again instead of pulling it When dismounting from the machine press the button to apply the brake with...

Page 35: ...ncy position Traveling 0 6 8 mile h 0 11 km h IMPORTANT Be sure to shift gears while the machine is stopped Cannot shift gears during operation NOTE Machine speed can be operated under at FULL positio...

Page 36: ...in vibratory mode IMPORTANT Do not operate the vibrator on a hard area such as cement concrete pavement surface or the ground covered by thick steel sheets Turn the vibrator off when the machine is at...

Page 37: ...itude NOTE Selection is applied only when the F N R lever is in the neutral position Vibration switch The vibration switch is integrated on the F N R lever The green button toggles vibration on and of...

Page 38: ...ray system is shut off AUTO position Spray system is actuated when the F N R lever is in the forward or reverse position and deactivated when the F N R lever is moved to the Neutral position Spray swi...

Page 39: ...ed for either the front or rear drum the second spray bar is operational When Both is selected for either the front or rear drum both spray bars operate providing double the volume of water going to w...

Page 40: ...limp home switch this function will only work after MANUALLY plugging in the appropriate wire harness connection See 2 3 4 Traveling page 50 for the detailed procedure on how to plug in the wire harn...

Page 41: ...PEED Vibration Spray switches are integrated on this lever IMPORTANT In an emergency depress the brake pedal Brake pedal In an emergency press the brake pedal to the full extent then the machine will...

Page 42: ...aveling Make sure the lock knob is turned counter clockwise fully then turn the hand knob clockwise fully than turn the lock knob clockwise to lock the handle It is now in the ONLOAD position WARNING...

Page 43: ...poor machine performance damage to the electrical system or safety problems such as an electrical fire See page 102 for location 2 2 Handling and Adjustments 2 2 1 Seat adjustment Adjust the seat for...

Page 44: ...ust the seat so that your back is in close contact with the back of the seat while seated and when stepping on the brake pedal down to the floor Adjust the seat so as to be able to certainly step on t...

Page 45: ...s developed in the hydraulic propulsion system disengage the brake as instructed below Use the same procedure for both front and rear drums 1 Remove the brake disengaging bolts and washers two each fr...

Page 46: ...become a little tight will disengage the brake NOTE Wash clean the brake release bolts and blank plugs before fitting to the motors 4 After towing replace the bolt and washer to original position and...

Page 47: ...to position 3 Continuing the same action while depressing the swivel lever will allow the operator s platform to lock automatically at 90 degrees WARNING Make sure the operator s platform is completel...

Page 48: ...ition to stop the engine 2 Set Engine diagnostic switch as shown in position 3 Turn the starter switch to the position to on the monitor display No fault codes recorded Light up the engine stop lamp a...

Page 49: ...of the center of the machine To unlock the bar Remove the spring pin Pull out the lock pin Set the bar in the carrying position Retain the lock bar in the locked position by inserting the lock pin in...

Page 50: ...al position and press down the parking brake switch before starting the engine Unless these conditions are met the engine will not start 1 Select IDLE position of Engine speed selector switch 2 Turn t...

Page 51: ...the fault 2 3 3 After starting the engine Try not to move the machine immediately after starting but practice the following IMPORTANT Avoid increasing the engine speed abruptly before warming up run i...

Page 52: ...y At FULL position of Engine speed selector switch position Traveling condition 0 6 8 mile h 0 11 km h NOTE Selection is applied only when the F N R lever is in the neutral position IMPORTANT Be sure...

Page 53: ...can be controlled by the engine speed select switch and F N R lever CAUTION Avoid abrupt operation of the F N R lever WARNING Pay extreme attention to the area behind the machine when backing since t...

Page 54: ...engine and make sure the emergency propel switch is in the neutral position 2 Identify the connectors PRO EME between the valve blocks on the left side of the machine 3 Remove the plugs from connecto...

Page 55: ...topping and parking WARNING Avoid abrupt braking Try to leave enough time for braking Avoid parking on a grade If necessary to park on a grade block the drums to prevent unexpected moving down the gra...

Page 56: ...he AUTO SPEED equal to the current machine speed 2 Check the AUTO SPEED lamp If the AUTO SPEED is successfully set up in Step 1 the AUTO SPEED lamp will remain lit If the lamp is not illuminated repea...

Page 57: ...p will flicker If the lamp is not flickering press the Top button again and hold for at least one second 3 Move back the F N R lever to neutral position AUTO SPEED is cancelled after the machine stops...

Page 58: ...while the machine is in motion 3 Remove the ignition key WARNING When dismounting from the machine apply the brake by pressing the parking switch button If necessary to park on a grade block the wheel...

Page 59: ...witch on the F N R lever AUTO position Vibration is automatically engaged when the F N R lever is moved into the forward or reverse positions 3 Select Vibration drum of Vibration drum selector switch...

Page 60: ...en lights on the EXACT COMPACT METER will light up when the machine speed matches the desired IPF number See 2 6 EXACT COMPACT Operation page 60 for more details NOTE Selection is applied only when th...

Page 61: ...ORTANT Use clean water wherever practicable 2 Select or AUTO position of Spray mode selector switch position Spray system can be controlled by the blue button switch on the F N R lever position Spray...

Page 62: ...spray switch When position is selected press the spray switch blue button and hold for at least one second and the system will start spraying The spray lamp will illuminate Pressing and holding the sp...

Page 63: ...rain cocks of water pumps Take off the bowl from water filters then throw away water in the bowl then put the bowl back on the water filters 5 Run the water pumps approximately 30 seconds with the dra...

Page 64: ...visually displayed by yellow green and red LED lights 2 Indicates the rolling speed 3 Indicates the error codes of the machine controller 4 Indicates the rolling surface temperature OPTION 2 6 2 Opera...

Page 65: ...ring to IPF numbers 1 Right green light 3 Difference comparing to IPF numbers 1 Red light Difference comparing to IPF numbers 3 2 Rolling speed Error codes Temperature display When the ignition key is...

Page 66: ...uld be performed at the rolling speed where the center green light stays illuminated 6 Using the AUTO SPEED function See page 52 will assist compaction work Following table shows reference with Freque...

Page 67: ...selector switch Broken wire Short circuit to machine controller No E22 IPF selector switch Broken wire Short circuit to machine controller No E31 Current control Propel pump solenoid for forward Curre...

Page 68: ...ing downhill Use the F N R lever Run slowly going downhill Do not use excessive speed Avoid changing speed if possible when going downhill Start slowly and end slowly on steep downgrades Use the engin...

Page 69: ...water from the machine Muds can get into the seals together with water drops on the hydraulic cylinder piston rod Damaged seals will result 2 Park the machine on a hard and dry surface If such a plac...

Page 70: ...loading use ramps or a proper loading stand 2 11 1 Use of a trailer equipped with a winch WARNING Placing the unloader valve in UNLOAD position disrupts the power for traction Do not enter the areas a...

Page 71: ...ve a proper space between the ramps according to the width of the roller drum 2 Decide the correct direction of run and conduct loading or unloading at low speed For loading run forward at low speed F...

Page 72: ...l with low viscosity See Rating on page 98 and 99 2 14 2 Coolant WARNING Do not bring an open flame to the antifreeze or do not smoke when handling it It is inflammable CAUTION Use ethylene glycol bas...

Page 73: ...ant to the bottom of the fill neck if needed 2 Start engine and run at mid speed for 1 minute or until engine warning lamp comes on 3 Turn off engine and top up coolant to bottom of fill neck if neede...

Page 74: ...nals with tools or other metallic objects Tangled terminals may generate sparks due to improper connections resulting in the danger of explosions Make sure terminals are connected firmly The battery i...

Page 75: ...ing the negative cable or take off the battery from the machine and store in a safe place 5 If the temperature is expected to go down below 0 C add antifreeze to the coolant 6 Completely drain the spr...

Page 76: ...allow a metallic item to bridge between the positive terminal and machine body This can generate sparks causing an explosion Loose battery terminals can cause sparks An explosion will result When conn...

Page 77: ...ve terminal when connecting the booster cables Wear safety goggles when jump staring the engine Do not allow the machine to make careless contact with the booster supply Do not make wrong connections...

Page 78: ...are to prevent dust from entering 4 For checking oil level or changing oil park the machine on a level and hard surface 5 Change oil while its temperature remains high after operation 6 For a long ter...

Page 79: ...placement maintenance part Replacement period Remarks 1 Brake system Master cylinder Seals rubber parts 2 years Wheel cylinder Seals rubber parts 2 years Brake piping parts Brake hose 2 years Air hose...

Page 80: ...center of machine CAUTION Remove ROPS before starting lifting work 1 Put wire ropes securely on the hook and lifting points as shown NOTE Use appropriate wire rope size 2 If wire ropes make contact w...

Page 81: ...7 3 2 Walk around Checking For efficient operation daily before operation checking is very important Before starting perform walk around checking for loose bolts nuts and signs of leakage in addition...

Page 82: ...3 PERIODIC MAINTENANCE 78 3 3 Periodic Maintenance Points...

Page 83: ...e hours Engine oil filter Change filter element 1 Sprinkler pipe Clean inside pipe 4 Vibrator Check oil level Gear oil 2 Rubber dampers Check for cracks 24 Engine oil pan Change engine oil Engine oil...

Page 84: ...is inclined please move it to the flat ground before start checking it WARNING It may cause scald immediately after that the engine is stopped because the temperature of the parts and the oils may be...

Page 85: ...es every year Fan belt Check the fan belt for wear and damage Replace as necessary IMPORTANT Please see the separate engine manual for engine for more details on fan belts WARNING Make certain that th...

Page 86: ...eck that there is no abnormality on the surface 3 Be sure to tighten the battery holder if it is loose CAUTION The power supply voltage of this machine is 12V Hydraulic oil level gauge Check the oil l...

Page 87: ...crankcase with the engine oil from the fill port 4 Change the engine oil filter element NOTE For a new machine change oil at 50 operating hours for the initial time only Sprinkler pipe 1 Spray pipe R...

Page 88: ...3 PERIODIC MAINTENANCE 84 Vibrator Check for the oil level and leakage Rubber dampers Check the rubber blocks for cracks and their mounting bolts for looseness...

Page 89: ...lter Fuel prefilter See the separate engine manual Change the fuel filter element and the fuel pre filter element Hydraulic oil line filter Change the line filter elements 2 pieces Control links Remov...

Page 90: ...IODIC MAINTENANCE 86 Tilt pin bearing Center pin bearing Apply grease at 6 locations Cylinder head and anchor pins Apply grease at 4 locations The steering cylinder is provided on both sides of the ma...

Page 91: ...ing a hot oil use care not to get burned Hydraulic oil suction filter Take off the hydraulic tank cover Take out and clean the strainer change the strainer if necessary Gear case Wheel motor 1 Positio...

Page 92: ...4 Rotate the roll until the mark on its inside comes to the bottom 5 Feed oil at filler port until oil flows out of level gauge hole 6 Reinstall the level gauge plug as well as filler oil plug after c...

Page 93: ...parts which will be exposed after removing the end cap It is recommended that O Rings are replaced with new ones 3 Blowing compressed air of 2 3 kgf cm2 into hole shown in sketch brake piston will com...

Page 94: ...e makes it impossible to reassemble 5 Install separate plate and friction plate alternately Be careful to install them in the correct quantity and order 6 Remove brake releasing port plug 19 across fl...

Page 95: ...ll as straightly as possible so that the shaft end does not damage journal bearing which has been press fit to end cap Tightening torque for the hex socket head bolt Tightening torque for the hex sock...

Page 96: ...her 1 When the braking force becomes weaker than driving force of hydraulic motor Despite that the brake is being actuated hydraulic motor rotates when HST drive is engaged Checking procedure While de...

Page 97: ...rlier 6 As needed Water tank 1 With the drain cap removed remove the water and sediment from the bottom of the tank 2 If sedimentation is substantial remove the drain plug and clean the interior of th...

Page 98: ...oose debris can fall into the air intake plumbing leading directly to the engine Clean the area around the secondary filter element and replace the secondary promptly to avoid engine contamination ing...

Page 99: ...nose Be sure to use our genuine element 4 Attach the element and service door it with a clips Breather See the separate engine manual Provide inspection and cleaning of the breather hoses and breather...

Page 100: ...ubject to change due to the improvements to the parts When ordering parts make sure to obtain the latest part numbers by checking with our distributorship or one of our certified service shops of the...

Page 101: ...3 PERIODIC MAINTENANCE 97...

Page 102: ...repair service 2 Capacity 3 Rating Lubricant Service classification Ambient temp and applicable viscosity rating Applicable standards 15 30 C 5 86 F Cold 0 40 C 32 104 F Moderate 15 55 C 59 131 F Trop...

Page 103: ...Engine oil API CJ4 Gear oil API GL 5 Hydraulic oil ISO VG 46 Grease NLGI 2 CHEVRON DELO 400 LE RPM Universal Gear Lubricants Rando HDZ 46 Martifak EP 2 BP BP Energear HYPO U Bartran HV 46 BP Energreas...

Page 104: ...3 PERIODIC MAINTENANCE 100...

Page 105: ...UTPUT A FOR OIL PRESS 15 STARTER LOCKOUT 16 WARNING LAMP 17 J1939 CAN 18 J1939 CAN 19 SWITCH RETURN 21 BATTERY 22 BATTERY 26 OEM SWITCH 28 CRUISE CONTROL RESUME INCREMENT SW 29 CRUISE CONTROL SET DECR...

Page 106: ...N Use fuses of correct capacity NOTE When a fuse is burned determine the cause befor replacing 3 9 Battery 1 Leaving the battery unused for long without attention or using its power excessively at a t...

Page 107: ...s so there is a danger of explosions Avoid recharging the battery keep cigarettes and flames away etc in poorly ventilated places when there is a danger of generating sparks The inspection and handlin...

Page 108: ...formance Travel speed 1st 2500 vpm 0 4 5 km h 0 2 8 mile h 3000 vpm 0 5 5 km h 0 3 4 mile h 4000 vpm 0 7 2 km h 0 4 5 mile h 2nd 0 11 km h 0 6 8 mile h Vibrating power Gradability 29 16 Rolling width...

Page 109: ...us 6 5 m 256 Vibrating power Low amplitude Frequency 66 7 Hz 50 0 Hz 41 7 Hz 4 000 vpm 3 000 vpm 2 500 vpm Centrifugal force 173 kN 98 kN 68 kN 38 890 lbs 22 030 lbs 15 285 lbs High amplitude Frequenc...

Page 110: ......

Page 111: ...Printed in Japan 2015 02 dataonly SAKAI HEAVY INDUSTRIES LTD Head Office 1 4 8 Shiba Daimon Minato ku Tokyo Japan Telephone 81 3 3431 9971 Facsimile 81 3 3436 6212...

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Sakai SW880-1, Operator'S Manual

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